Torque converter system and method of using the same

ABSTRACT

A torque converter includes a flywheel rotating about a first axis, the flywheel including a first body portion, a first plurality of permanent magnets mounted in the first body portion, each of the first plurality of permanent magnets extending along a corresponding radial axis direction with respect to the first axis, and a second plurality of permanent magnets mounted in the first body portion, each of the second plurality of permanent magnets being located between a corresponding adjacent pair of the first plurality of permanent magnets, and a generator disk rotatable about a second axis perpendicular to the first axis, the generator disk including a second body portion, and a third plurality of permanent magnets within the second body portion magnetically coupled to the first and second pluralities of permanent magnets.

The present application is a Continuation of U.S. Ser. No. 10/758,000filed on Jan. 16, 2004 now U.S. Pat. No. 6,930,421, which claims thebenefit of U.S. Provisional Patent Application No. 60/440,622 filed onJan. 17, 2003, all which are hereby incorporated by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a torque converter and a system using atorque converter. More specifically, the present invention relates to atorque converter that is capable of multiplying a given torque inputbased upon compression and decompression of permanent magnetic fields.In addition, the present invention relates to a system that uses atorque converter.

2. Discussion of the Related Art

In general, torque converters make use of mechanical coupling between agenerator disk and a flywheel to transmit torque from the flywheel tothe generator disk. However, due to frictional forces between thegenerator disk and the flywheel, some energy provided to the generatordisk is converted into frictional energy, i.e., heat, thereby reducingthe efficiency of the torque converter. In addition, the frictionalforces cause significant mechanical wear on all moving parts of thetorque converter.

SUMMARY OF THE INVENTION

Accordingly, the present invention is directed to a torque converterthat substantially obviates one or more of the problems due tolimitations and disadvantages of the related art.

An object of the present invention is to provide a torque converterhaving an increased output.

Another object of the present invention is to provide a system using atorque converter that reduces frictional wear.

Another object of the present invention is to provide a system using atorque converter that does not generate heat.

Another object of the present invention is to provide a system using atorque converter than does not have physical contact between a flywheeland a generator disk.

Another object of the present invention is to provide a system using atorque converter that allows an object to be inserted or reside betweena flywheel and a generator disk.

Additional features and advantages of the invention will be set forth inthe description which follows and in part will be apparent from thedescription, or may be learned by practice of the invention. Theobjectives and other advantages of the invention will be realized andattained by the structure particularly pointed out in the writtendescription and claims hereof as well as the appended drawings.

To achieve these and other advantages and in accordance with the purposeof the present invention, as embodied and broadly described, a torqueconverter includes a flywheel rotating about a first axis, the flywheelincluding a first body portion, a first plurality of permanent magnetsmounted in the first body portion, each of the first plurality ofpermanent magnets extending along a corresponding radial axis directionwith respect to the first axis, and a second plurality of permanentmagnets mounted in the first body portion, each of the second pluralityof permanent magnets being located between a corresponding adjacent pairof the first plurality of permanent magnets, and a generator diskrotatable about a second axis perpendicular to the first axis, thegenerator disk including a second body portion, and a third plurality ofpermanent magnets within the second body portion magnetically coupled tothe first and second pluralities of permanent magnets.

In another aspect, a system for generating electrical power includes amotor, a flywheel coupled to the motor, the flywheel rotating about afirst axis and including a first body portion, a first plurality ofpermanent magnets mounted in the first body portion, each of the firstplurality of permanent magnets extending along a corresponding radialaxis direction with respect to the first axis, and a second plurality ofpermanent magnets mounted in the first body portion, each of the secondplurality of permanent magnets being located between a correspondingadjacent pair of the first plurality of permanent magnets, at least onegenerator disk rotatable about a second axis perpendicular to the firstaxis and magnetically coupled to the flywheel, the generator diskincluding a second body portion, and a third plurality of permanentmagnets within the second body portion magnetically coupled to the firstand second pluralities of permanent magnets, and an electrical generatorcoupled to the generator disk.

In another aspect, a system for converting torque to power includes amotor, a flywheel coupled to the motor, the flywheel rotating about afirst axis and including a first body portion, a first plurality ofpermanent magnets mounted in the first body portion, each of the firstplurality of permanent magnets extending along a corresponding radialaxis direction with respect to the first axis, and a second plurality ofpermanent magnets mounted in the first body portion; each of the secondplurality of permanent magnets being located between a correspondingadjacent pair of the first plurality of permanent magnets, at least onegenerator disk rotatable about a second axis perpendicular to the firstaxis and magnetically coupled to the flywheel, each generator diskincluding a second body portion and a third plurality of permanentmagnets within the second body portion magnetically coupled to the firstand second pluralities of permanent magnets, and a second drive shaftcoupled to the second body portion rotating about the second axis.

It is to be understood that both the foregoing general description andthe following detailed description are exemplary and explanatory and areintended to provide further explanation of the invention as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are included to provide a furtherunderstanding of the invention and are incorporated in and constitute apart of this application, illustrate embodiments of the invention andtogether with the description serve to explain the principles of theinvention. In the drawings:

FIG. 1 is a layout diagram of an exemplary flywheel according to thepresent invention;

FIG. 2 is a layout diagram of an exemplary generator disk according tothe present invention;

FIG. 3 is a schematic diagram of exemplary magnetic fields of theflywheel of FIG. 1 according to the present invention;

FIG. 4 is a schematic diagram of an exemplary initial magneticcompression process of the torque converter according to the presentinvention;

FIG. 5 is a schematic diagram of an exemplary magnetic compressionprocess of the torque converter according to the present invention;

FIG. 6 is a schematic diagram of an exemplary magnetic decompressionprocess of the torque converter according to the present invention;

FIG. 7 is a schematic diagram of an exemplary magnetic force pattern ofthe flywheel of FIG. 1 during a magnetic compression process of FIG. 5according to the present invention;

FIG. 8 is a schematic diagram of an exemplary system using the torqueconverter according to the present invention; and

FIG. 9 is a schematic diagram of another exemplary system using thetorque converter according to the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Reference will now be made in detail to the illustrated embodiments ofthe present invention, examples of which are illustrated in theaccompanying drawings.

FIG. 1 is a layout diagram of an exemplary flywheel according to thepresent invention. In FIG. 1, a flywheel 109 may be formed from acylindrical core of composite material(s), such as nylon, and may bebanded along a circumferential edge of the flywheel by a non-magneticring 116, such as non-magnetic stainless steel or phenolic materials.The flywheel 109 may include a plurality of magnets disposed within aplurality of equally spaced first radial grooves 101 of the flywheel109, wherein each of the magnets may generate relatively strong magneticfields, such as 48 mgo_(e) (magnetic gauss orsted) or larger magnets. Inaddition, each of the magnets may have cylindrical shapes and may bebacked by a cylindrically shaped backing plate 203 (in FIG. 3), such assoft iron or steel, disposed within each of the plurality of firstradial grooves 101.

The magnets may be charged prior to installation within the plurality offirst radial grooves 101 of the flywheel 109 by applying approximately±485,500 watts of electricity (475 volts×1022 amps) to unchargedmaterial for approximately 0.01 seconds. Alternatively, the magnets maybe charged by application of specific amounts of power and/or specificperiods of time depending on the desire magnetic strength of themagnets.

In FIG. 1, the flywheel 109 may also include a plurality of suppressormagnets disposed within a plurality of second radial grooves 107 along acircumferential face of the flywheel 109, wherein surfaces of thesuppressor magnets may be recessed from the non-magnetic ring 116. Inaddition, each of the plurality of second radial grooves 107 may bedisposed between each of the plurality of first grooves 101. Forexample, each one of eight suppressor magnets may be disposed withineach of eight grooves 107 and each one of eight magnets may be disposedwithin each of eight grooves 101. Of course, the total number of magnetswithin the first and second grooves 101 and 107 may be changed.Accordingly, the suppressor magnets in the eight grooves 107 and themagnets in the eight grooves 101 of the flywheel 109 have their northmagnetic fields facing toward the circumference of the flywheel 109 andtheir south magnetic fields facing radial inward toward a center portionof the flywheel 109.

The backing plates 203 (in FIG. 3) disposed at end portions of themagnets disposed within the plurality of first grooves 101 at the southpoles of the magnets force a magnetic field strength along a radialdirection toward the circumference of the flywheel 109. Accordingly,interactions of the magnetic fields of the magnets within the pluralityof first grooves 101 and the suppressor magnets disposed within theplurality of second grooves 107 create a magnetic field pattern (MFP),as shown in FIG. 3, of repeating arcuate shapes, i.e. sinusoidal curve,around circumferential edge portions of the flywheel 109.

FIG. 2 is a layout diagram of an exemplary generator disk according tothe present invention. In FIG. 2, a generator disk 111, preferably madefrom a nylon or composite nylon disk, may be banded by a stainless steelring 112. The generator disk 111 may include two rectangular magnets 301opposing each other along a common center line CL through a centerportion C of the generator disk 111, wherein each of the rectangularmagnets 301 may be disposed along a circumferential portion of thegenerator disk 111. Each of the rectangular magnets 301 may have a firstlength L extending along a direction perpendicular to the common centerline, wherein a thickness of the rectangular magnets 301 may be lessthan the first length. In addition, each of the rectangular magnets 301may have a relatively large magnetic strength, such as about 48 mgoe ormore, wherein surfaces of the rectangular magnets 301 parallel to amajor surface of the generator disk may be one of south and north poles.Although the total number of magnets 301 is shown to be two, a pluralityof magnets 301 may be used. Moreover, either an even-number orodd-number of magnets 301 may be used, and interval spacings between themagnets 301 may be adjusted to attain a desired magnetic configuration.

FIG. 4 is a schematic diagram of an exemplary initial magneticcompression process of the torque converter according to the presentinvention, FIG. 5 is a schematic diagram of an exemplary magneticcompression process of the torque converter according to the presentinvention, and FIG. 6 is a schematic diagram of an exemplary magneticdecompression process of the torque converter according to the presentinvention. In each of FIGS. 4, 5, and 6, the schematic view is seen froma rear of the generator disk, i.e., the surface opposite to the surfaceof the generator wheel 111 having the rectangular magnets 301, and theflywheel 109 is located behind the generator wheel 111. In addition, theflywheel 109 is rotating in a downward clockwise direction and thegenerator wheel 111 is rotating along an upward counterclockwisedirection, wherein the generator disk 111 may be spaced from theflywheel 109 by a small air gap, such as within a range of aboutthree-eighths of an inch to about 0.050 inches. Alternatively, the smallair gap may be determined by specific application. For example, systemsrequiring a larger configuration of the flywheel and generator disk mayrequire larger or smaller air gaps. Similarly, systems requiring morepowerful or less powerful magnets may require air gaps having a specificrange of air gaps. Moreover, for purposes of explanation the pluralityof first grooves 101 will now simply be referred to as driver magnets101, and the plurality of second grooves 107 will now simply be referredto as suppressor magnets 107.

In FIG. 4, the two rectangular magnets 301 disposed on the generatordisk 111 begin to enter one of the spaces within a magnetic fieldpattern (MFP) of the flywheel 109 between two north poles generated bythe driver magnets 101. The driver magnets 101 may be disposed along acircumferential center line of the flywheel 109, or may be disposedalong the circumference of the flywheel in an offset configuration. Thegap between the driver magnets 101 in the flywheel 109 is a position inwhich the MFP where the south pole field is the closest to the outerperimeter of the flywheel 109. As the flywheel rotates along thedownward direction, the north poles of the rectangular magnets 301 onthe generator disk 111 facing the circumferential edge portion of theflywheel 109 are repelled by the north poles of the driver magnets 101of the flywheel 109.

In FIG. 5, once one of the rectangular magnets 301 on the generator disk111 fully occupies the gap directly between the north poles of twoadjacent driver magnets 101 of the flywheel 109, the weaker north poleof the suppressor magnet 107 on the flywheel 109 is repelled by thepresence of the north pole of the rectangular magnet 301 on thegenerator wheel 111. Thus, both the north and south magnetic fields ofthe MFP below the outer circumference of the flywheel 109 arecompressed, as shown at point A (in FIG. 7).

In FIG. 6, as the rectangular magnet 301 on the generator disk 111begins to rotate out of this position and away from the flywheel 109,the north pole of the rectangular magnet 301 is strongly pushed away bythe repulsion force of the north pole of the trailing driver magnet 101on the flywheel 109 and by the magnetic decompression (i.e., springback) of the previously compressed north and south fields in the MFPalong the circumferential portion of the flywheel 109. The spring backforce (i.e., magnetic decompression force) of the north pole in the MFPprovides added repulsion to the rectangular magnet 301 of the generatordisk 111 as the rectangular magnet 301 moves away from the flywheel 109.

Next, another initial magnetic compression process is started, as shownin FIG. 4, and the cycle of magnetic compression and decompressionrepeats. Thus, rotational movement of the flywheel 109 and the generatordisk 111 continues.

FIG. 8 is a schematic diagram of an exemplary system using the torqueconverter according to the present invention. In FIG. 8, a system forgenerating power using the torque converted configuration of FIGS. 4–7may include a motor 105 powered by a power source 101 using a variablefrequency motor control drive 103 to rotatably drive a shaft 407 coupledto the flywheel 109 (also shown in FIGS. 4–7). In addition, thegenerator disk 111 may be coupled to a drive shaft 113, wherein rotationof the generator disk 111 will cause rotation of the drive shaft 113.For example, a longitudinal axis of the drive shaft 113 may be disposedperpendicular to a longitudinal axis of the drive shaft 107.

In FIG. 8, the drive shaft 113 may be coupled to an electrical generatorcomprising a rotor 119 and a plurality of stators 117. Accordingly,rotation of the rotor 119 may cause the electrical generator to producean alternating current output to a variable transformer 121. Thus, theoutput of the variable transformer 121 may be provided to a load 123.

FIG. 9 is a schematic diagram of another exemplary system using thetorque converter according to the present invention. In FIG. 9, aplurality of the generator disks 111 may be clustered around and drivenby a single flywheel 109, wherein the generator disks 111 may each becoupled to AC generators similar to the configuration shown in FIG. 8.

The present invention may be modified for application to mobile powergeneration source systems, as drive systems for application in stealthtechnologies, as an alternative for variable speed direct drive systems,as drive systems for pumps, fans, and HVAC systems. Moreover, thepresent invention may be modified for application to industrial,commercial, and residential vehicles requiring frictionless, gearless,and/or fluidless transmissions. Furthermore, the present invention maybe modified for application in frictionless fluid transmission systemsthrough pipes that require driving of internal impeller systems.Furthermore, the present invention may be modified for application inonboard vehicle battery charging systems, as well as power systems foraircraft, including force transmission systems for aircraft fans andpropellers.

In addition, the present invention may be modified for application inzero or low gravity environments. For example, the present invention maybe applied for use as electrical power generations systems for spacestations and interplanetary vehicles.

It will be apparent to those skilled in the art that variousmodifications and variations can be made in the torque converter andsystem using the same of the present invention without departing fromthe spirit or scope of the inventions. Thus, it is intended that thepresent invention covers the modifications and variations of thisinvention provided they come within the scope of the appended claims andtheir equivalents.

1. A torque converter, comprising: a flywheel rotating about a firstaxis, the flywheel including a first plurality of permanent magnetswithin the flywheel and extending along a corresponding radial axisdirection with respect to the first axis; a generator disk spaced apartfrom the flywheel and rotatable about a second axis perpendicular to thefirst axis, the generator disk including a second plurality of permanentmagnets within the generator disk; and a third plurality of permanentmagnets located between the adjacent ones of the first plurality ofpermanent magnets within the flywheel, wherein at least one of thesecond plurality of permanent magnets is coupled between adjacent onesof the first plurality of permanent magnets when one of the flywheel andgenerator disk is rotated.
 2. The torque converter according to claim 1,wherein at least one of the third plurality of permanent magnets iscoupled between the adjacent ones of the first plurality of permanentmagnets when the one of the flywheel and generator disk is rotated. 3.The torque converter according to claim 2, wherein the coupling of theat least one of the second plurality of permanent magnets between theadjacent ones of the first plurality of permanent magnets when the oneof the flywheel and generator disk is rotated compresses magnetic fieldsof the at least one of the second plurality of permanent magnets, theadjacent ones of the first plurality of permanent magnets, and the atleast one of the third plurality of permanent magnets.
 4. The torqueconverter according to claim 3, wherein further rotation of the one ofthe flywheel and generator disk decompresses the magnetic fields of theat least one of the second plurality of permanent magnets, the adjacentones of the first plurality of permanent magnets, and the at least oneof the third plurality of permanent magnets.
 5. The torque converteraccording to claim 4, wherein the compression and decompression of themagnetic fields continues as the one of the flywheel and generator diskrotates.
 6. The torque converter according to claim 5, wherein therotation of the one of the flywheel and generator disk continues.
 7. Thetorque converter according to claim 1, wherein the at least one of thesecond plurality of permanent magnets occupies a gap directly betweenthe adjacent ones of the first plurality of permanent magnets.
 8. Thetorque converter according to claim 7, wherein each of the thirdplurality of permanent magnets are centered with the at least one of thesecond plurality of permanent magnets.
 9. The torque converter accordingto claim 1, further comprising a plurality of backing plates within theflywheel adjacent to the first plurality of permanent magnets.
 10. Atorque transfer system, comprising: a flywheel rotating about a firstaxis, the flywheel including a first plurality of permanent magnetswithin the flywheel and extending along a corresponding radial axisdirection with respect to the first axis; a generator disk rotatableabout a second axis perpendicular to the first axis, the generator diskincluding a second plurality of permanent magnets within the generatordisk; and a third plurality of permanent magnets within the flywheel andlocated between adjacent ones of the first plurality of permanentmagnets, wherein the first axis and second axis are coplanar.
 11. Thesystem according to claim 10, wherein rotation of one of the flywheeland generator disk causes one of the second plurality of permanentmagnets to occupy a gap between the adjacent ones of the first pluralityof permanent magnets.
 12. The system according to claim 11, whereinfurther rotation of the one of the flywheel and generator disk causesthe one of the second plurality of permanent magnets to vacate the gapbetween the adjacent ones of the first plurality of permanent magnets.13. The system according to claim 12, wherein additional rotation of theone of the flywheel and generator disk causes another one of the secondplurality of permanent magnets to occupy another gap between anotheradjacent ones of the first plurality of permanent magnets.
 14. Thesystem according to claim 13, wherein rotation of the one of theflywheel and generator disk continues.
 15. A torque transfer device,comprising: a flywheel rotating about a first axis, the flywheelincluding a first plurality of permanent magnets within the flywheel andextending along a corresponding radial axis direction with respect tothe first axis; and a generator disk rotatable about a second axiscoplanar with the first axis, the generator disk including a secondplurality of permanent magnets within the generator disk, whereinrotation of one of the flywheel and generator disk causes each of thesecond plurality of permanent magnets to continually occupy spacesbetween adjacent ones of the first plurality of permanent magnets.
 16. Amethod of transferring rotational motion from a first axis to a secondaxis perpendicular to the first axis, the method comprising: rotatingone of a flywheel about the first axis and a generator disk about thesecond axis, the flywheel including a first plurality of permanentmagnets within the flywheel and extending along a corresponding radialaxis direction with respect to the first axis, and the generator diskincluding a second plurality of permanent magnets within the generatordisk, wherein the rotation of the one of the flywheel and the generatordisk causes the other of the one of the flywheel and the generator diskto rotate by interaction of respective ones of the first and secondpluralities of permanent magnets by compression and decompression ofmagnetic fields of the first and second pluralities of permanentmagnets.
 17. The method according to claim 16, wherein the rotationcontinues as the compression and decompression of the magnetic fieldscontinues.